As a professional valve casting manufacturer and supplier based in China, Chongqing Sipx Machinery specializes in producing high-quality valve components through advanced casting techniques. Our valve casting process involves pouring molten metal into precision molds to create durable valve bodies, discs, and stems with exact specifications.

The valve casting manufacturing service is essential for producing reliable components that meet the demanding requirements of various industries, including oil and gas, chemical processing, water treatment, and power generation. Utilizing our foundry expertise, we create valve parts capable of withstanding extreme pressures, corrosive environments, and high-temperature conditions while ensuring long-term performance.

With years of experience in valve casting production, our China-based foundry combines traditional craftsmanship with modern technology to deliver components that exceed industry standards for durability and precision.

stainless casting valve

stainless casting valve

brass casting valve

brass casting valve

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casting valve meter part

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red paint casting valve

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casting valve with blue paint

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stainless valve casting parts

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Valve Casting Methods: Advanced Techniques by a Leading China Manufacturer

 

As a trusted valve casting supplier and foundry in China, Chongqing Sipx Machinery employs six proven casting methods to deliver precision-engineered valve components. Below are the valve casting processes we specialize in:

  1. Sand Casting
    The most widely used valve casting method globally, sand casting creates molds from bonded sand. Our foundry pours molten metal into these molds to produce robust valve bodies, discs, and stems ideal for high-temperature industrial applications.

  2. Investment Casting

    Perfect for complex valve geometries, this method uses wax patterns coated in ceramic shells. As a professional valve casting manufacturer, we melt the wax and inject molten metal to achieve exceptional surface finishes and tight tolerances.

  3. Die Casting
    Our high-pressure die casting service forces molten metal into reusable steel molds, ensuring mass production of uniform valve components with minimal post-processing.

  4. Lost Foam Casting
    This innovative valve casting technique uses evaporative foam patterns to create near-net-shape valve parts, reducing material waste and machining costs – a specialty of our China-based foundry.

  5. Continuous Casting
    For large-scale valve component production, we utilize continuous casting to form elongated metal profiles that are precision-cut to meet client specifications.

  6. Gravity die casting
    Combining excellent dimensional accuracy with smooth surface finishes, this method is ideal for aluminum and zinc alloy valves requiring intricate designs.

As an ISO-certified valve casting supplier in China, Chongqing Sipx Machinery selects the optimal casting method based on your component design, production volume, and performance requirements. Our valve casting services balance cost-efficiency with unmatched durability for oil/gas, chemical, and power generation industries.

Types of materials used for valve casting

 

Valve casting requires materials with high strength, corrosion resistance, and good wear resistance. The selection of materials for valve casting depends on the application, operating conditions, and the fluid or gas being handled. Some of the commonly used materials for valve casting include:

 

Materials

Detail

Carbon Steel

Carbon steel casting also called iron casting is a widely used material for valve casting due to its high strength, durability, and low cost. It is suitable for applications where the fluid or gas being handled is not corrosive.

Stainless Steel

Stainless steel is a popular choice for valve casting due to its excellent corrosion resistance, high strength, and durability. It is suitable for applications where the fluid or gas being handled is corrosive, such as in the chemical and petrochemical industries.

Alloy Steel

Alloy steel is a material that is used for valve casting in applications that require high strength and corrosion resistance. It contains other elements such as chromium, nickel, and molybdenum to improve its properties.

Brass and Bronze

Brass and bronze are copper-based alloys that are used for valve casting due to their excellent corrosion resistance, low friction, and good wear resistance. They are suitable for applications that involve water, steam, and other non-corrosive fluids.

Post processes after valve casting

 

As a professional manufacturer and supplier from China, we are committed to providing top – notch valve casting services. After valve casting, several crucial post – processes are often required to achieve the desired final product. These include:


    1. Machining: Machining is a vital process for valve casting. It involves removing excess material from the casting to attain the desired shape and dimensions. We utilize advanced tools like lathes, milling machines, and grinders to ensure precision machining of your valve castings. Our skilled technicians operate these machines with expertise to deliver castings that meet tight tolerances and exact specifications.

    2. Heat Treatment: Heat treatment is another essential post – process for valve casting. This process involves heating the casting to a specific temperature and then cooling it at a controlled rate. At our foundry in China, we have state – of – the – art heat treatment equipment and experienced personnel to optimize the mechanical properties of your valve castings. We can enhance the strength, hardness, and durability of your castings to meet the demanding requirements of various applications.

    3. Surface Treatment: Surface treatment plays a significant role in improving the performance and appearance of valve castings. We offer a variety of surface treatment options, including painting, plating, powder coating, and more. These treatments can enhance the corrosion resistance, wear resistance, and aesthetic appeal of your valve castings. Our surface treatment services are tailored to meet the specific needs of your application and industry standards.

    4. Assembly: After completing machining, heat treatment, and surface treatment, the valve casting may need to be assembled with other components to create the final valve product. Our experienced assembly team in China can handle this process efficiently and accurately. We ensure that all components are properly aligned and secured, guaranteeing the functionality and reliability of the final valve assembly.


Each of these post – processes is indispensable in achieving the desired final product and ensuring that the valve casting meets the specific requirements of the application. At Chongqing Sipx Machinery, we understand that the choice of post – processes depends on the particular needs of the valve casting and the demands of the application. Our comprehensive post – processing services are designed to add value to your valve castings and deliver products that perform reliably in their intended environments.

Different industries that use valve castings

 

Valve casting, as a crucial manufacturing process, produces valve components that are widely used across various industries. Below are some common applications:

  • Oil and Gas Industry: As a professional valve casting manufacturer and supplier from China, we produce valves that control the flow of oil and gas in pipelines, refineries, and petrochemical plants. Our valve castings are specifically designed to withstand high pressure, high temperature, and corrosive environments, ensuring reliable performance in this demanding industry.
  • Power Generation: Our China – based foundry provides valve casting services for power plants. The valves we produce are capable of controlling the flow of steam and water, designed to endure high temperature and pressure while preventing leaks and failures, which is essential for the safe and efficient operation of power generation facilities.
  • Chemical and Petrochemical Industry: We offer high – quality valve casting services for chemical and petrochemical processing plants. Our valve castings can handle corrosive and abrasive fluids and are built to withstand high temperature and pressure, meeting the strict requirements of this industry for material compatibility and durability.
  • Water Treatment: Our valve casting products are used in water treatment plants to control the flow of water and chemicals. The valves are constructed to handle corrosive and abrasive fluids, ensuring long – term functionality and minimal maintenance in water treatment applications.
  • Aerospace Industry: We provide precision valve casting services for the aerospace sector. The valves we produce for aircraft engines and hydraulic systems are engineered to withstand high temperature, high pressure, and harsh environments, meeting the exacting standards required for aerospace components.
  • Marine Industry: Our valve castings are utilized in marine applications such as shipbuilding, offshore drilling, and oil platforms. They are designed to withstand corrosive seawater and harsh marine environments, providing reliable performance in naval and offshore operations.

In summary, valve casting from Chongqing Sipx Machinery is a versatile manufacturing process that produces valve components used in various industries. These industries demand high – performance and reliability in severe – service applications. As a trusted China foundry and supplier, we are committed to delivering valve casting services that meet the specific needs of each industry, ensuring that our products perform effectively in their intended environments.

Chapter 1

Valve Precision Casting Molding System Design Practice

This section introduces targeted process measures taken in the design of the casting and feeding system for valve castings based on their structural and usage characteristics, with the aim of reducing defects such as looseness and shrinkage holes and improving the internal quality of the castings. Different casting system design schemes and empirical formulas for determining the dimensions of each part of the casting system are proposed based on the structural and dimensional characteristics of butterfly valve bodies, ball valve bodies, and gate valve bodies.

Valve castings must undergo pressure testing, and the requirements for their working and usage states determine that they cannot have looseness or shrinkage holes and must have good compactness. Therefore, the rationality of the casting and feeding system design is crucial.

1.1 Feeding and Shrinkage Form of Butterfly Valve Body

Butterfly valves represent a significant portion of valve castings and present considerable casting challenges. Our company, Chongqing Sipx Machinery, as a specialized China manufacturer and supplier in the foundry industry, has extensive experience in producing high – quality butterfly valve castings.
 
Figure 6 – 11 illustrates a tree diagram of a regular butterfly valve assembly, while Figure 6 – 12 presents a tree diagram of an irregular butterfly valve assembly. In the valve body, there are two long holes with a diameter of 25mm at both ends, which require subsequent processing. With the user’s consent, the long hole with the necked end is not cast, and a manifold feeding and shrinkage system is employed.
We adopt top injection vertical pouring, and the inner pouring channel is designed as a square with dimensions of 65mm × 65mm. The diameter of the riser is calculated as DR = 1.3D, resulting in a top diameter of 110mm. The height dimension is determined using the Lushi Yang formula: HR = DR（1 + 0.2h)/D = 135mm, with a cone angle of 58°0.
Thanks to the sufficient reserve metal liquid in our casting and feeding system, it can adequately supply the casting for feeding and shrinkage. This ensures that there are no looseness or shrinkage holes in the neck, and the process yield is remarkably high.
The irregular butterfly valve assembly shown in Figure 6 – 12 is essentially similar to Figure 6 – 11, with the only difference being the connection of a cube and a rectangular parallelepiped to the outer circle of the valve body at both ends. These additional components have relatively small dimensions. The hot spots are primarily located at the wall thickness of the valve body and the centroid of the geometry, with an equivalent thermal node diameter of approximately 31mm. We utilize the simplest top riser system, where the riser is replaced by the inner pouring channel. The top of the riser is directly connected to the transverse pouring channel, and the diameter of the riser is calculated as DR = 1.3b. The height dimension of the riser is determined by the formula: hR = DR[（1 + 0.1h)∕D – d).
 
Figure 6 – 13 depicts a tree diagram of a bottom – pouring butterfly valve assembly. This design is based on Figures 6 – 11 and 6 – 12 and is tailored to meet the requirements of casting two long holes with a diameter of 25mm, as well as incorporating a natural shrinkage section in the casting.
We adopt a structural design of a local feeding and shrinkage system using a bottom – pouring vertical pouring channel, also known as a split binary riser feeding and shrinkage system. In this setup, the molten metal flows through the straight pouring channel to the transverse pouring channel and then enters the inner pouring port from the bottom of the mold cavity. The metal gradually flows upward with smooth flow, effectively avoiding the formation of pores and slag inclusions. This design also ensures smooth exhaust and provides ample molten metal for feeding and shrinkage.
Furthermore, the amount of molten metal used in the straight and transverse pouring channels is minimized. These channels serve primarily as flow channels for molten metal pouring and feeding and shrinkage. This ensures smooth feeding and shrinkage during the solidification process of the casting, resulting in high yield and process efficiency of the castings.
As a professional valve casting supplier and foundry from China, we are dedicated to delivering high – quality butterfly valve castings that meet the stringent requirements of various industries. Our advanced casting techniques and rigorous quality control processes guarantee the reliability and performance of our products in demanding applications.

Figure-6-11：Valve wax mold diagram

The process parameters are as follows:

Inner gating thickness： h2=1.2D1=l.2X25=30mm

Inner gating width： b=h2

Transverse gating length： 115mm

Transverse gating thickness： h3=2/3h2

Riser height： h4=15mm

Sprue diameter： D=2.5D1=62.5mm

Sprue cone angle： 15°

Sprue neck height： h1=D1

Sprue height： h=3D1=75mm

The shape of the sprue neck is shown in Figure 6-13 A-A section.

1.2 Gating and feeding system for large-scale ball valve body casting

Valve casting, a crucial process in manufacturing valve components, is widely used across various industries. Chongqing Sipx Machinery, as a professional valve casting manufacturer and supplier from China, offers both sand casting and precision casting services to meet different customer requirements.

Casting Methods and Design Principles

The valve body is generally produced through sand casting; however, some customers may require precision casting for higher accuracy and finish. Figure 6 – 14 illustrates the tree diagram of a ball valve body, which comes in two different shapes: one with a protruding step inside the diameter and the other without. Regardless of the presence of a step, certain casting and feeding design principles should be followed.

Avoiding Horizontal Pouring

This type of casting should avoid horizontal pouring and instead adopt vertical pouring. For the feeding method, central direct gating and vertical gating should be avoided, while transverse gating and runner feeding are more appropriate. These design principles will be further explained through the analysis of the following casting structures.

Flange Components and Casting Method

From the sectional view in Figure 6 – 14, it can be seen that the component consists of two flange bodies connected by a cylindrical section. For flange components, the most common and effective casting method is employed. The feeding and shrinking system utilizes a top – gated transverse gating system. This system takes advantage of the gravity of the cylindrical cavity to generate a large static pressure head, ensuring sufficient molten metal for feeding and reducing the self – consumption of the riser metal.
In Figure 6 – 14, the inner gating connecting the flange bodies has dimensions of 100mm in diameter and 190mm in height. The large cross – section and high cooling modulus of the inner gating are necessary to accommodate the solidification shrinkage of the large casting.

Addressing Neck and Small Flange Feeding and Shrinking

The necks at both ends of the valve body are connected to two small flanges. To address the feeding and shrinking issues of the neck and small flanges, two additional risers are added, forming multiple sets of feeding and shrinking patterns. Views A and B in Figure 6 – 14 represent different riser sizes. The molten metal from the two risers is introduced through the transverse gating system, forming a “person” – shaped runner. This design also facilitates smooth investment removal, wax drainage, and venting during the precision casting process.

Shrinkage Cavities in Valve Bodies with Protrusions

Valve bodies with protrusions inside the diameter are prone to shrinkage cavities on the flat surfaces or intersections with a width of 14mm. This is due to the presence of thermal nodes, as indicated by the circle “De” in the sectional view of Figure 6 – 14. The diameter (CDc) of the internal tangent circle within this thermal node is approximately 22mm.

Calculation of Sprue Diameter and Height

Referring to the formulas for calculating the sprue diameter (D) and sprue height (h) based on the diameter of the internal tangent circle, these calculations are essential for designing an efficient feeding and shrinking system. As a leading valve casting foundry in China, Chongqing Sipx Machinery applies these principles to ensure the production of high – quality valve castings that meet industry standards and customer specifications. Our advanced casting techniques and rigorous quality control processes guarantee the reliability and performance of our products in various applications.

Figure 6-14 Ball valve body wax mold

D=(2.2~ 2. 5)Dc

h=(3~ 3.S )Dc 

Design a hidden riser with dimensions of 80mm X 60mm X 60mm. It is welded to the lower part of the thermal node and connected to the bottom plane of the transverse gating system. This form is adopted to eliminate shrinkage cavities and shrinkage defects in the casting.

The dimensions of the inner gating connecting the flange bodies for such castings are determined based on production experience. If the flange diameter is greater than 500mm, the width of the inner gating is 1/6 to 1/5 of the flange diameter, and the height of the inner gating is 1/3 to 1/4 of the flange diameter. If the flange diameter is less than 200mm, the width of the inner gating is 1.5/5 to 2/5 of the flange diameter, and the height of the inner gating is 1/4 to 1/5 of the flange diameter.

1.3 Pouring and shrinking system of gate valve body

he pouring and shrinking system of the gate valve body shares similarities with those of ball and butterfly valves, yet two distinct aspects deserve emphasis.

Transverse Gating System Design

Firstly, concerning the transverse gating system production, numerous manufacturers adopt a rectangular flat – bottomed design. However, in Figure 6 – 15, our company, Chongqing Sipx Machinery, a reputable valve casting manufacturer and supplier from China, showcases an improved design. The middle part of the transverse gating system is shaped into an arc, while the ends remain square. This innovative design allows molten metal to flow more smoothly and concentrate during pouring. Such an optimized gating system is crucial for achieving high – quality valve castings, ensuring minimal defects and maximizing the efficiency of the casting process.

Hidden Riser Design for Wall Thickness Adjustment

Secondly, there is a rectangular protrusion at the top of the gate valve body, as seen in the half – sectional view in Figure 6 – 15(a). This feature significantly increases the local wall thickness. Our foundry experts utilize this design to hide the riser for feeding and shrinkage under the arc of the transverse gating system. When the shell is formed, the coating connects them to create a hidden riser. This design not only enhances the feeding and solidification effects but also simplifies the riser cutting process after casting. As a professional valve casting foundry in China, we understand the importance of such details in producing reliable and durable gate valve castings that meet industry standards and customer requirements.

Application in Valve Cover Casting

Figure 6 – 16 presents the assembly tree diagram of the valve cover casting, where the transverse gating system also incorporates an arc – shaped design. This design choice ensures effective feeding and solidification, thereby improving the production efficiency and yield of the casting process. Chongqing Sipx Machinery, with our extensive experience and expertise in valve casting, continuously refines our casting techniques. We aim to deliver high – performance valve castings that can withstand the demanding conditions of various industrial applications. Our commitment to quality and innovation makes us a trusted supplier and foundry partner for valve casting needs.

1.4 Comparison of two valve plate feeding and solidification methods.

The gate plate assembly schemes can be seen in Figure 6-17 and Figure 6-18, with the same shape and dimensions. Only the feeding and solidification methods differ between the two. The feeding and solidification effect in Figure 6-17 is better than that in Figure 6-18.

 1.5 Design and calculation of risers

In the realm of valve casting, achieving an accurate understanding of the design and calculation methods of risers is crucial for eliminating shrinkage defects. As a professional valve casting manufacturer and supplier from China, we are deeply aware of the significance of this aspect.
 
With the continuous advancement of the machinery industry, there has been a growing demand for components with complex shapes, uneven wall thickness, and specific pressure requirements. These components often need to be produced through precision casting. This evolution has placed higher demands on the design of precision casting processes. If the gating and riser design is not promptly updated in response to changes in the casting structure, shrinkage defects may easily occur. Consequently, this can lead to an increased scrap rate and a higher need for welding repairs in the castings.
 
To address this challenge, our team of experts has initiated a comprehensive study based on the principles of metal crystallization and solidification. We have gathered and analyzed relevant technical information, integrating it with the design and calculation methods of gating and risers. Through rigorous research and practical application, we have achieved remarkable results in actual production. These findings not only enhance the quality and reliability of our valve castings but also serve as valuable references for our peers in the industry. As a leading foundry and supplier in China, Chongqing Sipx Machinery is committed to continuously improving our casting technologies and processes. Our goal is to meet the evolving needs of our customers and deliver high – performance valve castings that excel in precision and quality.
Sluice Valve body

（a）Sluice Valve body

Sluice valve bod wax mold

 (b) Sluice valve bod wax mold

 Figure 6-15: Sluice valve body

Figure 6-16: Sluice valve body casting cover

Formation mechanism and solutions for shrinkage and porosity. The formation process of shrinkage and porosity is mainly affected by the heat absorption of the mold shell and the temperature difference with the outside world when the liquid metal fills the mold cavity. A hard shell solidifies on the surface of the casting and tightly encloses the liquid metal inside. With further cooling, the hard shell becomes thicker and the liquid level follows to generate liquid and solidification.

As a result, a cone-shaped shrinkage and an axial porosity are formed at the thermal section, central area, and upper part. A complete gating and riser design system must be equipped around this area. To set up a reasonable gating and riser system, we should first start from the end area of the casting, determine the direction of sequential solidification, analyze the filling and non-filling areas, and then decide the position of the gating and riser. At the same time, the size of the gating and riser should be calculated according to the modulus method, and necessary allowances should be added if needed.

The compensation distance of the riser is the sum of the dense riser area and the dense end. The determination methods for the compensation distance include flat shape, square shape, step-shaped cocoon shape, circular shape, upright shape, etc., as shown in Figure 6-19 to Figure 6-21.

The modulus calculation method establishes a proportional relationship between the length of solidification and the volume V and surface area S of the casting. That is, Ma = VIS (mm), and this ratio Ma is called the solidification modulus of the casting. In process design, the modulus of the riser must be greater than the modulus of the casting at the compensating shrinkage section to ensure smooth supply of liquid metal from the riser to the casting. Considering fluid mechanics and physical chemistry theories, the ratio K between the riser modulus M_riser and the casting modulus M_casting should be greater than 1.3 to achieve better results.

The formulas for calculating the casting modulus can be found in Table 6-2. The constant proportion relationship among the casting modulus M_casting, the inner gate (riser neck) modulus M_inner, and the riser modulus M_riser is: M_casting : M_inner : M_riser = 1:1.2:1.3. In the case of high mechanical performance requirements, the proportion relationship is: M_casting : M_inner : M_riser = 1:1.3:1.5. By using the formulas, suitable dimensions for the riser and riser neck can be obtained from Table 6-3 and Table 6-4.

FAQ

Valve casting is the process of creating valves by pouring molten metal into a mold and allowing it to cool and solidify into the desired shape.

The most common materials used in valve casting are stainless steel, carbon steel, and alloys like bronze and brass.

Valve casting offers several advantages, including the ability to create complex shapes and designs, high precision and accuracy, durability, and the ability to produce large quantities of valves efficiently.

We make precision casting parts according to clients drawings or samples. Faucets fittings, valve settings, automotive spare parts are common made in our foundry.

We used stainless steel 304,304L,316,316L,410,416 and 17-4.

The most common types of valve casting are sand casting, investment casting, and die casting.

Valve casting is used in a variety of industries, including oil and gas, chemical processing, power generation, and water treatment.

The production capacity of our precision casting foundry can produce 50000pcs per month.

The process of valve casting involves creating a mold, melting the metal, pouring it into the mold, allowing it to cool and solidify, removing the mold, and finishing the valve with machining, polishing, and other processes.

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    • Office Add:  No.551, Baosheng Avenue, Huixing Street, Yubei District, Chongqing, China
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